Metal Plate Foundations with Integral Planar Fins

ABSTRACT

A metal foundation includes a plurality of metal plate bodies coupled together forming the metal foundation, each metal plate body being comprised of lateral ends with integrated planar fins, wherein each of the lateral ends overlap a lateral end of an adjacent metal plate body, wherein the plurality of the metal plate bodies are configured for forming a closed perimeter of a geometrical shape having an open interior and wherein the integrated planar fins of each metal plate body extends away from the perimeter of the closed geometric shape along the plane of the planar fin, wherein each planar fin has a thickness substantially the same as a thickness of the portion of the metal plate body forming the closed perimeter of the geometrical shape, and wherein each planar fin extends substantially along a single plane from the perimeter of the closed geometric shape.

RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No. 14/827,477 filed Aug. 17, 2015, titled “Non-Welded Metal Foundation”, which published Feb. 11, 2016 as Publication 2016-0040386, and issued May 14, 2019 as U.S. Pat. No. 10,287,742 which publication and patent are incorporated herein by reference.

U.S. patent application Ser. No. 14/827,477 is a continuation of U.S. patent application Ser. No. 13/907,121 filed May 31, 2013, entitled “Non-Welded Metal Foundation”, which published Dec. 5, 2013 as Publication 2013-0322970, which publication is incorporated herein by reference.

U.S. patent application Ser. No. 13/907,121 claims the benefit of U.S. Provisional Patent Application Ser. No. 61/653,781, filed May 31, 2012, and entitled “Non-Welded Metal Foundation” which is herein incorporated by reference.

BACKGROUND INFORMATION 1. Field of the Invention

The present invention relates to metal foundations and more specifically to foundations formed of metal plates having a closed perimeter and integral fins.

2. Background Information

Metal foundations have been used to provide support for many different types of structures, because they offer many advantages over concrete foundations. Once installed, metal foundations can be used to instantly provide support for a structure, unlike concrete foundations which require a significant amount of time to cure. Metal foundations also can be installed in any weather condition and on any terrain; they are less damaging to the environment and they are easily moved when compared to concrete foundations.

However the current metal foundations that are available have several disadvantages. Current metal foundations have fins that are not integrated into the metal foundation bodies and welding is used for assembly. Welding, either on site or offsite requires qualified people and special equipment. This adds to the expense of installing foundations. Usually because it is less expensive, the metal foundation bodies are welded together in a shop and then transported on to the worksite. Transporting pre-assembled metal foundations limits their size and shape. If the metal foundations necessary for a specific project are too large or awkward to transport, the individual pieces can be weld together on site. However, this increases the expense of installing metal foundations because all the necessary personnel and equipment must also be transported to the worksite. Welding also generates toxic fumes which is not healthy for people or environmentally friendly.

There is a need in the art to provide alternative metal foundations.

SUMMARY OF THE INVENTION

In order to overcome these deficiencies in the prior art, the present invention provides a metal foundation includes a plurality of metal plate bodies coupled together forming the metal foundation, each metal plate body being comprised of lateral ends with integrated planar fins, wherein each of the lateral ends overlap a lateral end of an adjacent metal plate body, wherein the plurality of the metal plate bodies are configured for forming a closed perimeter of a geometrical shape having an open interior and wherein the integrated planar fins of each metal plate body extends away from the perimeter of the closed geometric shape along the plane of the planar fin, wherein each planar fin has a thickness substantially the same as a thickness of the portion of the metal plate body forming the closed perimeter of the geometrical shape, and wherein each planar fin extends substantially along a single plane from the perimeter of the closed geometric shape.

James Tappe, a co-inventor of the parent application, helped develop one aspect of this disclosure in which the metal foundation bodies are assembled together without welding wherein the fins are part of the metal foundation body. The bodies of the metal foundation of the disclosed invention are assembled manually via the integrated fins by mechanical fastening. The metal foundations of the invention can either be a perimeter geometric shape, a radial geometric shape or if the job requires, both shaped foundations can be combined/used in conjunction with one another. The mechanical fastening mechanism in this non-welded embodiment can be any known in the field including, but not limited to Huck Bolts, rivets, clips, bolts, studs and clamps. The advantage of this non-welded aspect of the invention is that it only requires manual assembly and not welding. The manual assembly can be done by persons generally familiar with the construction field and no special equipment other than that necessary for mechanical fastening is needed. Because the metal foundations according to this aspect of the invention are manually assembled, they are not a health hazard and they are more environmentally friendly than welded metal foundations.

With the disclosed invention there is virtually no limitations on size and shape for a metal foundation, the design can be easily adapt to any engineering specification. The metal foundations of the disclosed invention can be pre-assembled and transported to the worksite for installation or they can be assembled onsite.

The features that characterize the present invention are pointed out with particularity in the claims which are part of this disclosure. These and other features of the invention, its operating advantages and the specific objects obtained by its use will be more fully understood from the following detailed description taken together with the associated figures.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1A is a top plan view, partially exploded, of one embodiment of a metal plate foundation with integral planar fins according to one aspect of the invention.

FIG. 1B is a longitudinal side elevation view of the embodiment of an assembled metal plate foundation with integral planar fins of FIG. 1A.

FIG. 2A is a top exploded plan view of one embodiment disclosing a radial fin metal plate foundation.

FIG. 2B is a top plan view of the assembled radial fin metal plate foundation of FIG. 2A.

FIG. 3A is a schematic top plan view of a three sided metal plate foundation with integral planar fins further including a three fin radial metal plate foundation assembly according to one aspect of the invention.

FIG. 3B is a schematic top plan view of a nine sided metal plate foundation with integral planar fins further including a three fin radial metal plate foundation assembly according to one aspect of the invention.

FIG. 3C is a schematic top plan view of a six sided metal plate foundation with integral planar fins further including a three fin radial metal plate foundation assembly according to one aspect of the invention.

FIG. 3D is a schematic top plan view of an eight sided metal plate foundation with integral planar fins further including a four fin radial metal plate foundation assembly according to one aspect of the invention.

FIG. 3E is a schematic top plan view of a twelve sided metal plate foundation with integral planar fins further including a four fin radial metal plate foundation assembly according to one aspect of the invention.

FIG. 3F is a schematic top plan view of a four sided metal plate foundation with integral planar fins further including a four fin radial metal plate foundation assembly according to one aspect of the invention.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Metal foundations are better than concrete foundations because once installed, metal foundations can provide instant support for a structure on worksite.

However, current metal foundations have the disadvantage in that they require welding. This adds to the added expense of installing metal foundations. Welding also produces toxic fumes which are unhealthy and bad for the environment. James Tappe, a co-inventor of the parent application, helped develop one aspect of the present disclosed invention which eliminates the welding expense and hazards by providing for metal foundations that can be manually assembled. The metal foundations of this aspect of the disclosed invention are manufactured with the fins integrated into the finished bodies. These metal foundations are assembled via the fins by any mechanical fastening known in the art including but not limited to Huck Bolts, rivets, clips, bolts, studs and clamps.

FIG. 1A is a top plan view, partially exploded, of one embodiment of a metal plate foundation with integral planar fins according to one aspect of the invention wherein an octagonal shape metal plate foundation is disclosed. At the ends of body 1 are long fins 3 and short fins 4. In one aspect, the individual bodies are assembled together by fasteners 2. However because the metal foundations of the disclosed invention is assembled out of bodies with integrated fins, the metal foundations can be any practical shape necessary; from a hexagon shape for a smaller foundation, to a virtually limitless number of sides to accommodate larger foundation designs. The size of the angle in the body 1 is dependent on the size of the foundation and the number of bodies necessary to accommodate the specific size. Larger foundations generally require more sides which increases the number of bodies necessary. The more bodies that are necessary the more obtuse can be the angle or the angle can be eliminated in favor of an arc to accommodate cylindrical designs.

While FIG. 1A depicts bodies with short fins as well as long fins which lower the cost of the bodies, the invention also contemplates exclusively using long fins. To assemble the metal foundation, the fins from separate bodies are joined. In one aspect this may be by a mechanical fastening such as Huck Bolts, rivets, clips, bolts, studs clamps or any other feasible mechanical connection known in the art. As depicted in the metal foundation 5 disclosed in FIG. 1B, the bottom of the foundation can be cut or mitered to a viable shape to penetrate the earth for a specific project.

FIG. 2 depicts a radial geometric embodiment of the disclosed metal plate foundation. In FIG. 2B, the radial metal plate foundation 12 is comprised of three fins that are centrally connected. In one aspect they may be connected via a mechanical fastener 13 forming a triangular radial shape. Each of fins 6 has one formed end 7 and a peripheral end 8 and fin 9 is a completely straight fin with a central end 11 and a peripheral end 10. When assembled, each of the formed ends 7 of fins 6 adjoin with the central end 11 of fin 9 to form a geometrically triangular radial metal foundation with three fins. The invention also contemplates the use of greater than three fins in a radial metal plate foundation. The fins are adjoined by any suitable method, including in one aspect of the invention by Huck Bolts, rivets, clips, bolts, studs clamps or any feasible method known in the art.

The invention also contemplates metal plate foundations using a combination of both the perimeter and radial geometric designs. Radial geometric foundations can be any number of fins as long as they match the segments of the perimeter foundation bodies. For instance, a three fin radial foundation such as that depicted in FIG. 2B will match any perimeter body shape that is divisible by three as shown by the preferred embodiments depicted in FIGS. 3A-C and a four point radial foundation assembled with only straight fins 9 and fastening means 13 will match any perimeter body shape divisible by four as shown by the preferred embodiments depicted in FIGS. 3D-F. The triangular radial foundation depicted in FIG. 2B is shown in use with a three sided foundation in FIG. 3a , a nine sided foundation in FIG. 3b , and a six sided foundation in FIG. 3c . A four point radial foundation is shown in use with an eight sided foundation in FIG. 3d , a twelve sided foundation in FIG. 3e and a four sided foundation depicted in FIG. 3f . These designs give a very strong and supportive foundation. These are some of the preferred embodiments; the invention is flexible that the pieces can be assembled in any feasible shape needed for a specific project. The fins of the radial metal foundation embodiments connect via the fins of the perimeter metal foundations by any suitable fashion, including mechanical devices such as Huck Bolts, rivets, clips, bolts, studs clamps or any feasible method known in the art.

The disclosed invention allows for a lot of flexibility in engineering designs for foundations. Any practicable size, shape, thickness or length can be accommodated by the disclosed invention. The metal foundations of the disclosed invention can be comprised of sheet or plate steel with any grade and thickness necessary to meet the load requirements of a specific project. The manufacturing methods used to make the bodies of the metal foundation are those commonly known in the art.

The metal foundations of the disclosed invention may, in one aspect, have the advantage of manual assembly, thus eliminating the need for welding. This in turn, eliminates a significant cost in the installation of metal foundations. If small enough, the metal foundations of the disclosed invention can be assembled in one place and transported to the work site. Alternatively for larger foundations, the individual pieces can be transported and manually assembled at the worksite as no special equipment other than that necessary for mechanical fastening is needed. The metal foundations of the disclosed invention can be installed in the ground to any depth by any means known in the art including but not limited to vibrating, pushing, or driving.

The foregoing discussion discloses and describes merely exemplary embodiments of the present invention. One skilled in the art will readily recognize from the accompanying drawings and claims that various changes or modifications can be made without departing from the spirit and scope of this invention. While the invention has been shown in several particular embodiments it should be clear that various modifications may be made to the present invention without departing from the spirit and scope thereof. The scope of the present invention is defined by the appended claims and equivalents thereto. 

What is claimed is:
 1. A metal foundation comprising: a plurality of metal plate bodies coupled together forming the metal foundation, each metal plate body being comprised of lateral ends with integrated planar fins, wherein each of the lateral ends overlap a lateral end of an adjacent metal plate body; wherein said plurality of said metal plate bodies are configured for forming a closed perimeter of a geometrical shape having an open interior and wherein the integrated planar fins of each metal plate body extends away from the perimeter of the closed geometric shape along the plane of the planar fin, wherein each planar fin has a thickness substantially the same as a thickness of the portion of the metal plate body forming the closed perimeter of the geometrical shape, and wherein each planar fin extends substantially along a single plane from the perimeter of the closed geometric shape.
 2. The metal foundation according to claim 1 wherein a longitudinally lower end of at least a plurality of the metal plate bodies is angled relative to a normal to a longitudinal axis of the metal plate body.
 3. The metal foundation according to claim 1 wherein each metal plate body is comprised of sides forming an obtuse angle, wherein the closed geometrical shape is a polygon.
 4. The metal foundation according to claim 3 wherein the polygon has sides of equal widths.
 5. The metal foundation according to claim 3 wherein the polygon is an octagon.
 6. The metal foundation according to claim 1 wherein each metal plate body is arced along a portion thereof forming a cylindrical perimeter geometric design.
 7. The metal foundation according to claim 1 wherein each metal plate body on one said lateral end is comprised of a long integrated fin and on a second opposed said lateral end is comprised of a short integrated fin having a length measured from the closed perimeter of the geometrical shape along the single plane less than the long integrated fin.
 8. A metal foundation comprising: a plurality of metal plate bodies coupled together forming the metal foundation, each metal plate body being comprised of lateral ends with integrated planar fins, wherein each of the lateral ends overlap a lateral end of an adjacent metal plate body; wherein said plurality of metal plate bodies are configured for forming a closed perimeter of a geometrical shape having an open interior and wherein the integrated planar fins of each metal plate body extends away from the perimeter of the closed geometric shape along the plane of the planar fin, wherein each planar fin has a thickness substantially the same as a thickness of the portion of the metal plate body forming the closed perimeter of the geometrical shape, and wherein each planar fin extend substantially along a single plane from the perimeter of the closed geometric shape, wherein each metal plate body on one said lateral end is comprised of a long integrated planar fin and on a second opposed said lateral end is comprised of a short integrated planar fin having a length measured from the closed perimeter of the geometrical shape along the single plane less than the long integrated planar fin, and wherein each long planar fin of one metal plate body is adjacent a short planar fin of an adjacent metal plate body.
 9. The metal foundation according to claim 8 wherein a longitudinally lower end of at least a plurality of the metal plate bodies is angled relative to a normal to a longitudinal axis of the metal plate body.
 10. The metal foundation according to claim 9 wherein each metal plate body is comprised of sides forming an obtuse angle, wherein the closed geometrical shape is a polygon.
 11. The metal foundation according to claim 10 wherein the polygon has sides of equal widths.
 12. The metal foundation according to claim 10 wherein the polygon is an octagon.
 13. The metal foundation according to claim 9 wherein each metal plate body is arced along a portion thereof forming a cylindrical perimeter geometric design.
 14. A radial fin metal plate foundation comprising: a plurality of radial fins formed of metal plates, wherein each radial fin includes a central lateral end and a distal lateral end, and wherein a portion of each central lateral end of each radial fin overlaps with a portion of a central lateral end of adjacent radial fins, wherein the distal lateral end of each radial fin is a radial distance from the overlapped central lateral ends and wherein each radial fin extends along a plane from adjacent the overlapped portion to the distal lateral end.
 15. The metal foundation according to claim 14 wherein the radial fin metal plate foundation is comprised of exactly three fins.
 16. The metal foundation according to claim 14 wherein the radial fin metal plate foundation is comprised of exactly four fins.
 17. The metal foundation according to claim 14, wherein a longitudinally lower end of at least a plurality of the radial fins are angled relative to a normal to a longitudinal axis of the radial fin. 